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Newbie in trouble: "Check hybrid system"

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by RogerHq, May 22, 2015.

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  1. RogerHq

    RogerHq Junior Member

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    Well, the battery packs are the same AFAIK, it will come next week.
    The error codes looks slightly different in my list, I'm not sure what the" Interlock switch" means, There is an orange thing on the battery pack I thougth it was the 120A fuse?
    P0571 is listed, as I have mentioned, under the cruise control header, is that wrong?
     
    #21 RogerHq, May 30, 2015
    Last edited: May 30, 2015
  2. bisco

    bisco cookie crumbler

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    it might be different, but i wouldn't take the dealers word for it. perhaps someone from europe can help, or when you open the battery up, you can compare.
     
    #22 bisco, May 30, 2015
  3. bisco

    bisco cookie crumbler

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    the orange thing is the interlock switch. there is a specific method for closing it when you wrap things up. it's not intuitive, and the car won't become ready if you do it incorrectly.
     
    #23 bisco, May 30, 2015
  4. wjtracy

    wjtracy Senior Member

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    You might want to PM GrumpyCabbie who knows a lot about EU Prii.
    We've had almost no Gen3 batt failures in the USA on PriusChat.
    However, EU Gen3 taxis have had some battery and inverter issues, you'll see a bunch of threads on that.
     
    #24 wjtracy, May 30, 2015
  5. RogerHq

    RogerHq Junior Member

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    Used Hybrid battery pack approaching... How to install?
     
    #25 RogerHq, Jun 1, 2015
  6. JC91006

    JC91006 Senior Member

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    There's an excellent video at Dorman hybrid website
     
    #26 JC91006, Jun 1, 2015
  7. RogerHq

    RogerHq Junior Member

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    Thanks for warning me Bisco ;-)
     
    #27 RogerHq, Jun 1, 2015
  8. RogerHq

    RogerHq Junior Member

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    Thanks JC
    Looked at the GenII Installation, seems rather straightforward, differences to GenIII is I guess minor.
     
    #28 RogerHq, Jun 1, 2015
  9. RogerHq

    RogerHq Junior Member

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    Hybrid Battery arrived! Now, How to Install? There is some obvious physical differences between GenII and GenIII.....
     
    #29 RogerHq, Jun 2, 2015
    Last edited: Jun 2, 2015
  10. RogerHq

    RogerHq Junior Member

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    Still covered in plastic foil... IMG_2977.JPG
     
    #30 RogerHq, Jun 2, 2015
  11. RogerHq

    RogerHq Junior Member

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    IMG_0630.jpg I hope it will look like this, the broken one....
     
    #31 RogerHq, Jun 2, 2015
  12. RogerHq

    RogerHq Junior Member

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    Another question is if some prepraratory measurements can be made before installation using a simple Voltmeter?
     
    #32 RogerHq, Jun 2, 2015
  13. Patrick Wong

    Patrick Wong DIY Enthusiast

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    The physical design of the G2 and G3 traction battery cases differ. So you will need to open both units, and substitute battery modules from the newly arrived battery case into your original equipment battery case.
     
    #33 Patrick Wong, Jun 2, 2015
  14. RogerHq

    RogerHq Junior Member

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    Well, this might be true for US vehicles but late 2009 cars in Sweden appear to have the same battery pack. Their physical appearance are the same and the part number too. My battery is unpacked and tested now and my meter reads 217 Volt DC from two thick cables coming from the cell stack, that's fine to me. Now I might need the installation procedure for the G3 car or maybe it's just to do it:

    1) Remove the orange thing
    2) Remove all cables (but first make sure no High Voltage are left on the main power cables and connectors)
    3) Remove all relevant Nuts&Bolts
    4) Change packs
    5) Inverse 3-2-1

    Or maybe I should disconnect 12V first?
     
    #34 RogerHq, Jun 3, 2015
    Last edited: Jun 4, 2015
  15. RRxing

    RRxing Senior Member

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    2009 Prius in Europe = Gen III
    2010 Prius in USA = Gen III
     
    #35 RRxing, Jun 3, 2015
  16. Mendel Leisk

    Mendel Leisk Senior Member

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    I like the picture of your car. It looks to be still a cab at heart. :)

    Yes, you need to disconnect the 12 volt battery early in the process. Here's instruction for North American third generation Prius, hopefully very similar:
     

    Attached Files:

    #36 Mendel Leisk, Jun 3, 2015
  17. RogerHq

    RogerHq Junior Member

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    Thanks Mendel!
    I read the 30 pages, well most of them, it looks familiar, there will be some investigation and disassembly tomorrow.

    Yes, I like my yellow cab, there are 1300 of them in Stockholm from different carmakers, a lot of them are Toyota Prius!

    / Roger
     
    #37 RogerHq, Jun 3, 2015
  18. RogerHq

    RogerHq Junior Member

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    Resetted the error state and run the the car some weeks only to return to the same error. That was of course expected. Alas, today the car refused to start and I have to dig into this thing again, wish me luck!
     
    #38 RogerHq, Jul 3, 2015
  19. SageBrush

    SageBrush Senior Member

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    ^^ Good Luck!

    You will be so much better off with a VCI cable and software to read DTC codes.
     
    #39 SageBrush, Jul 3, 2015
  20. RogerHq

    RogerHq Junior Member

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    Hybrid Battery successfully replaced but the system ignores it. According to the manual "some systems have to be initialized" So how do I do that?
     
    #40 RogerHq, Jul 3, 2015
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